Method for producing nanosurfaces with nano, micron, and/or submicron structures on a polymer

Abstract

The present invention relates to a modified polymeric material. The modified polymeric material includes a polymer having a modified surface, where the modified surface includes nano, micron, and/or submicron scale features. The present invention also relates to an implant comprising the modified polymeric material. The present invention further relates to processes for making the modified polymeric material and the implant.

What is claimed is: 
     
       1. A process for preparing a modified polymeric material, said process comprising:
 providing a polymer, wherein the polymer is polyetheretherketone (PEEK); and 
 subjecting the polymer to a high vacuum treatment regimen under conditions effective to modify a surface of the polymer by introducing to the surface of the polymer features selected from the group consisting of nanoscale features, micron scale features, and submicron scale features, 
 wherein said high vacuum treatment regimen comprises simultaneously heating the polymer at a temperature of between 275° C. and 400° C. and incubating the polymer in a vacuum chamber under high vacuum conditions in a range of 10 −2  Torr to 10 −6  Torr effective to modify the surface of the polymer,
 wherein said subjecting comprises: 
 (a) loading the polymer at a first temperature; 
 (b) increasing the temperature during a ramp-up period to a second temperature of 275° C. to 400° C.; 
 (c) maintaining the polymer at the second temperature; 
 (d) then, decreasing the temperature by 125° C. to 250° C. during a ramp-down period to a third temperature; and 
 (e) after the ramp-down period, extracting the polymer. 
 
 
     
     
       2. The process according to  claim 1 , wherein the first temperature is about 150° C. 
     
     
       3. The process according to  claim 1 , wherein the second temperature is about 275° C. to about 350° C. 
     
     
       4. The process according to  claim 1 , wherein the third temperature is about 150° C. 
     
     
       5. The process according to  claim 1 , wherein the ramp-up period is performed over the course of about 1 hour. 
     
     
       6. The process according to  claim 1 , wherein the polymer is maintained at the second temperature for about 1 hour. 
     
     
       7. The process according to  claim 1 , wherein the ramp-down period is performed over the course of about 1 hour. 
     
     
       8. The process according to  claim 1 , wherein said incubating is carried out for at least 5 hours. 
     
     
       9. The process according to  claim 1 , further comprising storing the extracted polymer under high vacuum conditions in a range of 10 −2  Torr to 10 −6  Torr for about 8 hours. 
     
     
       10. The process according to  claim 1 , further comprising at least one of:
 applying an acid etching procedure either before or after the polymer is modified; and 
 integrating or coating the modified polymeric material with another material to yield a two layer or integration of the modified polymeric material and the other material. 
 
     
     
       11. The process according to  claim 10 , wherein the other material comprises hydroxyapatite, titanium, or calcium. 
     
     
       12. The process according to  claim 1 , wherein the polymer is in the form of a polymeric film, fiber, sphere, ovoid, rod, filament, monofilament, or scaffold, plug, or matrix. 
     
     
       13. The process according to  claim 1 , wherein said modified polymeric material is effective to modify a biological response, fixation, or a therapeutic attachment/delivery compared to a corresponding non-modified polymeric material. 
     
     
       14. The process according to  claim 13 , wherein said modified polymeric material is effective to modify the biological response, and the biological response is selected from the group consisting of protein or antibody adsorption, cell attachment, cell function, and tissue growth. 
     
     
       15. The process according to  claim 13 , wherein said modified polymeric material is effective to modify the therapeutic attachment/delivery, and the therapeutic is selected from the group consisting of a peptide, protein, growth factor, antibody, drug, metal, antimicrobial metal, antibiotic metal, biologic tissue, biologic agent, chemical agent, stem cell, and modified cell. 
     
     
       16. The process according to  claim 1 , wherein the modified polymeric material further comprises at least one of:
 a functional attachment effective to increase biological response or therapeutic attachment/delivery; and 
 a ceramic, metal, or another polymer integrated into the modified polymeric material or coated onto the surface of the modified polymeric material. 
 
     
     
       17. The process according to  claim 16 , wherein the functional attachment is selected from the group consisting of a peptide, protein, growth factor, antibody, drug, metal, antimicrobial metal, antibiotic metal, biologic tissue, biologic agent, chemical agent, stem cell, and modified cell. 
     
     
       18. A process for making an implant, said process comprising preparing a modified polymeric material according to  claim 1 , and forming an implant comprising the modified polymeric material. 
     
     
       19. The process according to  claim 18 , wherein the implant is a spine cage, vertebral body replacement, suture anchor, dental implant, or maxillofacial implant.